Thermal protection packaging

ABSTRACT

A blank for forming an insulated carton including a front panel hingedly attached to a first side panel, the first side panel hingedly attached to a rear panel, the rear panel hingedly attached to a second side panel along a longitudinal axis of a blank, wherein each panel includes a central portion disposed between and hingedly attached to at least one flap arranged transverse to the longitudinal axis, an end tab hingedly attached to the central portion of the second side panel, and wherein the blank defines an interior space of a carton when folded along each hinged attachment and at least one surface of the blank includes a reflective barrier for energy-insulating the interior space of the carton.

BACKGROUND Technological Field

The present disclosure relates to insulating blanks for marking cartons and inserts for insulating cartons, and more particularly to blanks and inserts having a reflective barrier.

Description of Related Art

A variety of devices are known in the art for providing thermal protection to products being shipped.

The conventional methods and systems have generally been considered satisfactory for their intended purpose. However, there is still a need in the art for containers to minimize energy transfer with the outside. There also remains a need in the art for such containers to be economically viable. The present disclosure may provide a solution for at least one of these remaining challenges.

SUMMARY

A blank for forming an insulated carton includes a front panel hingedly attached to a first side panel, the first side panel hingedly attached to a rear panel, the rear panel hingedly attached to a second side panel along a longitudinal axis of a blank, wherein each panel includes a central portion disposed between and hingedly attached to at least one flap arranged transverse to the longitudinal axis, an end tab hingedly attached to the central portion of the second side panel, and wherein at least one surface of the blank includes a reflective barrier for energy-insulating the interior space of the carton and the blank defines an interior space of a carton when folded along each hinged attachment. Each of the panels can be different lengths, each of the panels can be of equal widths.

The flap of each panel can be indirectly attached to at one flap of an adjacent panel. The flap of the front panel and the at least one flap of the rear panel can be rectangle shaped, and the at the flap of the first side panel and the flap of the second side panel can be trapezoid shaped.

The end tab can include a central portion disposed between and hingedly attached to two opposing flaps arranged transverse to the longitudinal axis.

The reflective barrier can face the interior space and an outwardly facing surface of the end tab which does not include a reflective barrier can be attached to the reflective barrier of the front panel when the carton is erected. It is also conceived that the end tab can be located on the outside of the carton when assembled.

An insulating insert for a carton includes a frontal layer, including a reflective barrier for energy-insulating the interior space of a carton, attached to a middle layer including at least one layer of corrugated cardboard and attached to a rear layer, and a top side, a first side, a second side, and a bottom side defining an outer perimeter of the insert, wherein the top side and the bottom side each include at least one notch and at least one tab for mating with a second insert or third insert.

The at least one tab of the top side can include two tabs aligned asymmetrically with respect to a length of the top side and the at least one tab of the bottom side can include two tabs aligned asymmetrically with respect to a length thereof. The at least one notch of the top side can also include two notches symmetrically disposed along a length of the top side and the at least one notch of the bottom side can include two notches symmetrically disposed along a length of the bottom side.

A second insert can be detachably attached to a side of the first insert, wherein when the second insert can be detached and the rear layer of the first insert can abuts the rear layer of the second insert. The tabs of the two inserts can be of unequal height.

The reflective barrier of the insert can face an interior space defined if the insert is joined with another five inserts, it is also considered that the reflective barrier faces away from the interior space. The at least one tab of the bottom side of the first insert can interlock with the at least one notch of the top side of the second insert.

A system of inserts for insulating a carton includes a top insert, a bottom insert, a frontal insert, a rear insert, a first side insert, and a second side insert each including a frontal layer including a reflective barrier, for energy-insulating the interior space of the carton, attached to a middle layer including at least one layer of corrugated cardboard and attached to a rear layer. The top, bottom, a frontal, a rear, first side, and second side inserts define an interior space when the top, bottom, a frontal, a rear, first side, and second side inserts are mated together. Each of the top, bottom, a frontal, a rear, first side, and second side inserts include a top side, a first side, a second side, and a bottom side defining an outer perimeter thereof, wherein the top side of the top insert includes two tabs configured for mating with two notches of a frontal insert and the bottom side of the top insert includes two tabs configured for mating with notches of a rear insert, wherein the frontal insert and the rear insert are wider than the top insert and the bottom insert.

The reflective barrier of the embodiments mentioned above can include an optical density greater than 2.0, can include metalized polyester, and can be laminated to the insert.

These and other features of the systems and methods of the subject disclosure will become more readily apparent to those skilled in the art from the following detailed description of the preferred embodiments taken in conjunction with the drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

So that those skilled in the art to which the subject invention appertains will readily understand how to make and use the devices and methods of the subject invention without undue experimentation, preferred embodiments thereof will be described in detail herein below with reference to certain figures, wherein:

FIG. 1 is a top view of a blank for forming an insulated carton, showing a surface with a reflective barrier for a full overlap container;

FIG. 1a is a perspective view of portion 1A of FIG. 1, showing the reflective layer of the blank.

FIG. 1b is a perspective view of a carton formed from the blank of FIG. 1, showing a carton with open flaps;

FIG. 2 is a top view of a blank for forming an insulated carton, showing a surface with a reflective barrier for a full overlap container;

FIG. 2a is a perspective view of portion 2A of FIG. 2, showing the reflective layer of the blank.

FIG. 2b is a perspective view of a carton formed from the blank of FIG. 2, showing a carton with open flaps;

FIG. 3 is an exploded view of insulating inserts for a carton;

FIG. 4 is a partially exploded view of the insulating inserts of FIG. 5, showing being placed in the carton;

FIG. 5 is a perspective view of an insulating insert of FIG. 3, showing the insert in a pre-folded stage.

FIG. 5a is a perspective view of a detail 5A of FIG. 5, showing connection of the two portions of the insert.

FIG. 5b is a perspective view of an insulating insert of FIG. 5, showing the insert in a folded stage.

FIG. 5c is a perspective view of a detail 5C of FIG. 5b , showing connection of the two portions of the insert.

FIG. 6 is a perspective view of an insulating insert of FIG. 3, showing an insert in a pre-folded stage.

FIG. 6a is a perspective view of an insulating insert of FIG. 6, showing the insert in a folded stage.

FIG. 7 is a perspective view of an insulating insert of FIG. 3, showing an untabbed insert in a pre-folded stage.

FIG. 7a is a perspective view of an insulating insert of FIG. 7, showing the insert in a folded stage.

DETAILED DESCRIPTION

Reference will now be made to the drawings wherein like reference numerals identify similar structural features or aspects of the subject invention. For purposes of explanation and illustration, and not limitation, a partial view of an exemplary embodiment of a blank for forming an insulated carton in accordance with the invention is shown in FIG. 1 and is designated generally by reference character 100. Other embodiments of blanks for forming an insulated carton in accordance with the invention, or aspects thereof, are provided in FIGS. 2-9A, as will be described. The systems of the invention can be used to increase the insulation of cartons and reduce production costs.

Referring to FIGS. 1-1 b, a blank 100 for forming an insulated carton includes a front panel 102 hingedly attached to a first side panel 104, the first side panel 104 hingedly attached to a rear panel 106, the rear panel 106 hingedly attached to a second side panel 108 along a longitudinal axis 110 of the blank 100, wherein each panel 102-108 includes a central portion 1020, 1040, 1060, 1080 disposed between and hingedly attached to at least one flap 1021, 1041, 1061, 1081, arranged transverse to the longitudinal axis 110, an end tab 112 hingedly attached to the central portion 1080 of the second side panel 108, and wherein at least one surface of the blank includes a reflective barrier 114, for energy-insulating the interior space the carton, and the blank 100 defines an interior space 116 of a carton when folded along each hinged attachment. The reflective barrier has a higher thermal radiation reflectance than an underlying layer. Each of the panels can be different lengths L1-L4, each of the panels can be of equal widths W1. The lengths L1-L4 of the flaps vary in order to accommodate the thickness of the reflective barrier 114. The flap of each panel can be indirectly attached to a flap of an adjacent panel, each of the panels being rectangular.

The reflective barrier 114 can face the interior space 116 and an outwardly facing surface 115 of the end tab 112 which does not include a reflective barrier can be attached to the reflective barrier 114 of the front panel 102 when the carton is erected. The reflective barrier 114, can be used for both keeping energy within the carton and for keeping excess energy from entering from the outside. Also, the panels 102-108 of the blank 100 are folded in such a way so as to minimize the airflow into and out of the carton. The carton can be airtight when folded properly.

Referring to FIGS. 2-2 b, the flaps of the front panel 2021, 2022 and the at flaps of the rear panel 2061, 2062 can be rectangle shaped, and the flaps of the first side panel 2041, 2042 and the flaps of the second side panel 2081, 2082 can be trapezoidal shaped. The end tab 212 can include a central portion 2120 disposed between and hingedly attached to two opposing flaps 2121, 2122 arranged transverse to the longitudinal axis 210. Panels 202 and 206 can be approximately the equal lengths, and panels 204 and 208 can be approximately equal lengths. All panels 202-208 can include differing lengths. The flap of each panel can be at least partially directly attached to a flap of an adjacent panel. It is also conceived that the end tab 212 can be located on the outside of the carton when assembled.

Referring to FIGS. 3 and 4, system of inserts for insulating a carton includes a top insert 302, a bottom insert 304, a frontal insert 306, a rear insert 308, a first side insert, and a second side insert 312. The top 302, the bottom 304, the frontal 306, the rear 308, the first side 310, and the second side 312 inserts define an interior space 304 when the inserts 302-312 are mated together. Each of the top 302, bottom 304, a frontal 306, a rear 308, first side 310, and second side inserts 312 include a top side, a first side, a second side, and a bottom side defining an outer perimeter thereof, wherein the top side of the top insert 3021 includes two tabs 320 configured for mating with two notches 322 of a frontal insert 308 and the bottom side 3023 of the top insert 302 includes two tabs 324 configured for mating with two notches 326 of a rear insert 306, wherein the frontal insert 308 and the rear insert 306 are wider than the top insert 302 and the bottom insert 304. The two side inserts 310, 312 can be without locking features. The two side inserts 310, 312 can be shorter than the front 308 and rear 306 inserts, and be less wide than then top 302 and bottom 304 inserts. The tabs 320, 324 and notches 322 of the two inserts are of unequal height, allowing the insert to be locked mated together without a tab 320, 324 protruding past a notch 322.

Referring to FIGS. 5-7 a, each inset includes a frontal layer including a reflective barrier 314 attached to a middle layer 315 including at least one layer of corrugated cardboard and attached to a rear layer 316. The top side of the insert shown in FIG. 5-5 c includes two tabs 320 aligned asymmetrically with respect to a length L9 of the top side. The insert shown in FIG. 5-5 c corresponds to the top 302 and bottom 304 inserts of FIG. 3. The insert shown in FIG. 6-6 a includes two notches 322 symmetrically disposed along a length L12. The insert shown in FIG. 6-6 a corresponds to the front 306 and rear 308 inserts of FIG. 3 The insert shown in FIG. 7-7 a does not include notches, tabs, or other locking features. The insert shown in FIG. 7-7 b corresponds to the first side 310 and the second side 312 inserts of FIG. 3. It is also conceived that the inserts can be arranged to form an interior space without being interlocked by the tabs and notches. The inserts can fit together and be further held in place by the carton.

Referring further to FIGS. 5-7 b a second insert 303 is detachably attached to a side of the first insert 302. The second insert 303 can be attached at a first side. The second insert 307 can be attached at a bottom side. The second insert 303 can be identical to the first insert 302. The second insert 303 is folded such that the rear layer 316 of the first insert 302 abuts the rear layer 316 of the second insert 303. The reflective barrier 314 of each first insert faces the interior space 401, and the reflective barrier 314 of each second insert 303 faces away from the interior space 401. This arrangement ensures that energy loss and gain are limited to the interior space 401. When assembled, the inserts minimize airflow into and out of the interior space. It is also conceived that the reflective barrier 314 faces the exterior, to provide further energy efficiency. The interior space can be airtight when folded the inserts are assemble properly. The reflective barrier of the embodiments mentioned above include an optical density greater than 2.0, can include metalized polyester, and are be laminated to the insert.

The methods and systems of the present disclosure, as described above and shown in the drawings, provide for an insulating system with superior properties including increased energy. While the apparatus a of the subject disclosure have been showing and described with reference to embodiments, those skilled in the art will readily appreciate that changes and/or modifications may be made thereto without departing from the spirit and score of the subject disclosure. 

What is claimed is:
 1. A blank for forming an insulated carton comprising: a front panel hingedly attached to a first side panel, the first side panel hingedly attached to a rear panel, the rear panel hingedly attached to a second side panel along a longitudinal axis of a blank, wherein each panel includes a central portion disposed between and hingedly attached to at least one flap arranged transverse to the longitudinal axis; an end tab hingedly attached to the central portion of the second side panel; and wherein the blank defines an interior space of a carton when folded along each hinged attachment and at least one surface of the blank includes a reflective barrier which has a higher thermal radiation reflectance than an underlying layer for energy-insulating the interior space of the carton.
 2. The blank of claim 1, wherein each of the panels are different lengths.
 3. The blank of claim 1, wherein each of the panels are equal widths.
 4. The blank of claim 1, wherein the at least one flap of each panel is indirectly attached to the at least one flap of an adjacent panel.
 5. The blank of claim 1, wherein the at least one flap of the front panel and the at least one flap of the rear panel are rectangular, and the at least one flap of the first side panel and the at least one flap of the second side panel are trapezoidal.
 6. The blank of claim 1, wherein the end tab includes a central portion disposed between and hingedly attached to two opposing flaps arranged transverse to the longitudinal axis.
 7. The blank of claim 1, wherein the reflective barrier is configured to face the interior space when the carton is erected.
 8. The blank of claim 7, wherein an outwardly facing surface of the end tab does not include a reflective barrier and is attached to the reflective barrier of the front panel.
 9. An insulating insert for a carton comprising: a frontal layer including a reflective barrier which has a higher thermal radiation reflectance than an underlying layer for energy-insulating the interior space of the carton attached to a middle layer including at least one layer of corrugated cardboard and attached to a rear layer; and a top side, a first side, a second side, and a bottom side defining an outer perimeter of the insert, wherein the top side and the bottom side each include at least one notch and at least one tab configured for mating with a second insert.
 10. The insert of claim 9, wherein the at least one tab of the top side includes two tabs aligned asymmetrically with respect to a length thereof and the at least one tab of the bottom side includes two tabs aligned asymmetrically with respect to a length thereof.
 11. The insert of claim 9, wherein the at least one notch of the top side includes two notches symmetrically disposed along a length thereof and the at least one notch of the bottom side includes two notches symmetrically disposed along a length thereof.
 12. The insert of claim 9, further comprising a second insert detachably attached to a side thereof, wherein when the second insert is detached and the rear layer of the first insert abuts the rear layer of the second insert.
 13. The insert of claim 12, wherein the tabs of the two inserts are of unequal height.
 14. The insert of claim 9, wherein the reflective barrier of the insert faces an interior space defined by the insert being joined with another five inserts.
 15. The insert of claim 9, wherein the reflective barrier of the insert faces away from an interior space by the insert being joined with another five inserts.
 16. The insert of claim 15, wherein the at least one tab of the bottom side interlocks with the at least one notch of the top side.
 17. A system of inserts for insulating a carton comprising: a top insert, a bottom insert, a frontal insert, a rear insert, a first side insert, and a second side insert each including a frontal layer including a reflective barrier which has a higher thermal radiation reflectance than an underlying layer for energy-insulating the interior space of the carton attached to a middle layer including at least one layer of corrugated cardboard and attached to a rear layer; the top, bottom, a frontal, a rear, first side, and second side inserts defining an interior space when mated together; wherein each of the top, bottom, a frontal, a rear, first side, and second side inserts includes a top side, a first side, a second side, and a bottom side defining an outer perimeter thereof, wherein the top side of the top insert includes two tabs configured for mating with two notches of a frontal insert and the bottom side of the top insert includes two tabs configured for mating with notches of a rear insert; wherein the frontal insert and the rear insert are wider than the top insert and the bottom insert.
 18. The blank of claim 1, wherein the reflective barrier includes an optical density greater than 2.0.
 19. The insert of claim 9, wherein the reflective barrier includes metalized polyester.
 20. The insert of claim 9, wherein the reflective barrier is laminated to the insert. 